Fence system with pultruded rail sections

ABSTRACT

A fence system includes hollow post structures and upper and lower rail structures each comprising a hollow rail and a rail mounting bracket for mounting the rail to each post structure. Hollow balusters may also extend between the upper and lower rail structures. At least one of the hollow structural members, preferably including each of the rails, includes a pultruded structure and preferably a topcoat which is co-extruded with the pultruded structure. The pultruded structure provides substantially increased strength and the topcoat a highly colorable and long-wearing decorative outer layer, the latter preferably formed of acrylic or polyvinyl chloride. The rail mounting brackets are preferably injection molded with a substrate and a topcoat which matches the topcoat of the structural members.

BACKGROUND OF THE INVENTION

1. Technical Field

The invention relates generally to a fencing system or railing system. More particularly, the invention relates to such a system which includes hollow structural members including a pultruded structure. Specifically, the invention relates to such structural members wherein the pultruded structure serves as a substrate which is coated by an extruded decorative top coat.

2. Background Information

The field of fencing systems and railing systems includes configurations which include generally hollow members, in particular the posts and rails extending therebetween. This may also include balusters which extend between upper and lower rails. These various structural members are typically extruded and most often are made of various types of plastic materials. One of the drawbacks with such fencing systems is the difficulty in providing high-strength members, especially with regard to the rails. In addition, the decorative layers of such structural members is typically very thin and thus is easily scratched off or worn away. Alternately, the decorative outer layers have colors that fade in the weather, particularly with regard to degradation by sunlight. The present invention solves these and other problems, as will be discerned by the following description.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a fencing system comprising: a first post; a first rail mounted on the post; and at least one of the post and the first rail including a pultruded structure.

A preferred embodiment provides an extruded top coat on the at least one of the post and first rail.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a fragmentary elevational view of a first embodiment of the fence system of the present invention.

FIG. 2 is a sectional view taken on line 2-2 of FIG. 1.

FIG. 3 is a sectional view taken on line 3-3 of FIG. 1.

FIG. 4 is a sectional view of the rail mounting bracket shown in the inset portion of FIG. 1 taken from the direction as viewed in FIG. 1.

FIG. 5 is an enlarged sectional view of a portion of FIG. 1 showing the post mount within the hollow post and the mounting of the rail brackets and rails on the post.

FIG. 6 is a fragmentary elevational view of a second embodiment of the fence system of the present invention.

FIG. 7 is a sectional view taken on line 7-7 of FIG. 6.

Similar numbers refer to similar parts throughout the specification.

DETAILED DESCRIPTION OF THE INVENTION

A first embodiment of the fence system of the present invention is indicated generally at 100 in FIG. 1 and a second embodiment is indicated generally at 200 in FIG. 6. Fence system 100 includes a pair of posts 102 which are adapted to mount on a foundation 104 such as the ground, a floor, or any of various types of platforms. System 100 further includes an upper rail structure 106 including an upper rail 108 and a pair of upper rail mounting brackets 110A and 110B mounted on each post 102. System 100 further includes a lower rail structure 112 including a lower rail 114 and a pair of lower rail mounting brackets 116A and 116B mounted on each post 102. A cap member 118 is seated atop each post 102.

Each post 102 (FIG. 1) has an upper end 120 and a lower end 122 adjacent which post 102 is mounted on foundation 104. Each post 102 is hollow and elongated in a vertical direction between upper end 120 and lower end 122. Each post 102 has four substantially flat sides 124 (three shown in FIG. 1) with a respective upper rail mounting bracket 110A and a lower rail mounting bracket 116A mounted on one side 124 and a respective upper rail mounting bracket 110B and lower rail mounting bracket 116B mounted on another side 124 opposite thereto.

Each upper rail 108 (FIG. 1) has a first end 126 mounted on and supported by a respective first upper rail mounting bracket 110A and a second end 128 mounted on and supported by an upper rail mounting bracket 110B whereby upper rail 108 extends substantially horizontally between a pair of adjacent posts 102. Each upper rail 108 is hollow and elongated between first end 126 and 128. Likewise, lower rail 114 has a first end 130 mounted on and supported by lower rail mounting brackets 116A and a second end 132 mounted on and supported by lower rail mounting bracket 116B whereby lower rail 114 extends substantially horizontally between the pair of adjacent posts 102. Each lower rail 114 is hollow and elongated between first end 130 and second end 132.

With reference to FIG. 2 and in accordance with a feature of the invention, each post 102 includes a pultruded structure 134 which serves as a substrate and a top coat 136 adhered thereto. Pultruded structure 134 includes an inner surface 138 defining an interior chamber 140 and an outer surface 142. Top coat 136 has an outer surface 144 and an inner surface 146 which is adhered to and in particular strongly bonded to outer surface 142 of pultruded structure 134.

Pultruded structure 134 includes a glass matting or mesh formed of any of a variety of glass fibers such as fiberglass embedded in a thermoset resin material. The matting and resin are pulled through a dye to produce the final configuration of pultruded structure 134. Top coat 136 is a plastic material which is most preferably an acrylic material or alternately a PVC polymer. An acrylic material is thus preferred because it may be colored to produce dark colors which are substantially non-fading in sunlight or other weather conditions. Preferably, top coat 136 is extruded and most preferably simultaneously with pultruded structure 134. It might be said that top coat 136 is co-extruded with pultruded structure 134, meaning that structure 134 is formed by pultrusion at the same time that top coat 136 is being formed by extrusion whereby top coat 136 is firmly bonded to pultruded structure 134 during this simultaneous formation process. Materials formed by this process may be obtained from Omega Pultrusions Incorporated of Aurora, Ohio.

In accordance with a feature of the invention and with reference to FIG. 3, upper rail 108 is described. It is noted that lower rail 114 has the same structure as upper rail 108 and is therefore not separately described. Upper rail 108 includes a pultruded structure 148 which serves as a substrate and a top coat 150 adhered thereto. Pultruded structure 148 has an inner surface 152 defining an interior chamber 154 and an outer surface 156. Top coat 150 has an outer surface 158 and an inner surface 160 which is adhered to and more particularly firmly bonded to outer surface 156 of pultruded structure 148. Pultruded structure 148 is formed of the same materials in the same manner as described with regard to pultruded structure 134 and top coat 150 is formed of the same materials in the same manner as described with regard to top coat 136.

In accordance with a feature of the invention and with reference to FIG. 4, rail mounting bracket 110A is further detailed. It is noted that rail brackets 110B, 116A and 116B are either identical to or mirror images of bracket 110A and are therefore not described separately from bracket 110A. Bracket 110A includes a base structure or substrate 162 which is preferably formed by injection molding and a top coat 164 also preferably formed by injection molding. Most preferably, substrate 162 and top coat 164 are formed by two-shot injection molding within a single mold. Substrate 162 of bracket 110A includes a substantially flat base wall 166 and a collar 168 extending outwardly therefrom to form an interior chamber 170 opening outwardly from base wall 166. Base wall 166 and collar 168 define a pair of counterbore holes 172 disposed on opposite sides of interior chamber 170. Hole 172 includes a first narrower section 174 and a second wider counterbore section 176. Bracket 110A has an outer surface 178 which includes a visible surface 180 which is visible when bracket 110A is mounted on a post 102 and rail 108 is mounted on bracket 110A. Outer surface 178 further includes a non-visible surface 182 which is hidden from sight when system 100 is assembled. Thus, top coat 164 is bonded to only a portion of base structure 162 so that visible surface 180 is formed entirely by top coat 164. Visible surface 180 extends into the wider counterbore section 176 of each counterbore hole 172. Non-visible surface 182 is substantially free of top coat 164. Non-visible surface 182 includes the portion of base structure 162 which defines interior chamber 170 as well as respective narrower sections 174 of counterbore holes 172. Non-visible surface 182 further includes the portion of base wall 166 which is disposed adjacent post 102 facing one of sides 124 thereof (FIG. 5). While top coat 164 may extend onto non-visible surface 182 as well, it is preferred that top coat 164 is only applied to form visible surface 180, especially where top coat 164 is formed of an expensive material such as an acrylic material, which is the preferred material for the formation of top coat 164. Typically, base structure 162 is formed of an ABS polymer or PVC polymer.

With reference to FIG. 5, the mounting of upper rail structure 106 is detailed. It is noted that lower rail structure 112 is mounted in the same fashion. System 100 is mounted using a post mount 184 which is adapted to mount to foundation 104 (FIG. 1). Post mount 184 includes a vertically elongated side wall 186 and upper and lower projections 188 and 190 respectively. Upper projection 188 extends outwardly and then downwardly from side wall 186 and includes an outermost edge 192. Likewise, lower projection 190 extends outwardly and then downwardly from side wall 186 and has an outermost edge 194.

Each post 102 (FIG. 5) is mounted on a respective post mount 184 whereby post mount 184 is slidably received in interior chamber 140 of post 102 with outermost edges 192 and 194 of respective projections 188 and 190 abutting inner surface 138 of post 102. A pair of holes 125 is formed in each of a pair of opposed sides 124 of post 102. Upper rail mounting bracket 110A is mounted on one of said sides 124 of post 102 with a pair of fasteners in the form of screws 127 which extend through respective counterbore holes 172 in bracket 110A and into respective holes 125 with which screw 127 is threadably engaged. Likewise, mounting bracket 110B is mounted on the opposed side 124 in the same fashion. One of upper rails 108 is mounted on rail mounting bracket 110A with first end 126 disposed within interior chamber 170 closely adjacent or in contact with base wall 166 of bracket 110A. Similarly, another upper rail 108 is mounted on mounting bracket 110B with second end 128 thereof disposed within interior chamber 170 closely adjacent or in contact with base wall 166.

With continued reference to FIG. 5, it is noted that cap member 118 may also be formed in a similar manner to that of mounting brackets 110. More particularly, cap member 118 includes a base structure or substrate 195 and a top coat 196 mounted thereon in the same fashion as described with regard to rail mounting bracket 110. Substrate 195 includes an inner surface 197 which defines a downwardly opening cavity 198 in which upper end 120 of post 102 is received when cap member 118 is mounted atop post 102. As previously noted, cap member 118 may be formed in a similar fashion as described with regard to rail mounting brackets 110 whereby substrate 195 is injection molded and top coat 196 is injection molded as well and preferably by a two-shot injection process within a single mold.

With reference to FIG. 6, fence system 200 is further detailed. System 200 is similar to system 100 except that it includes upper and lower rail structures which differ from the rail structures of system 100 and also includes balusters extending between the upper and lower rail structures. Thus, system 200 uses a plurality of posts 102 having upper end 120 and lower end 122. A base member 202 may be mounted adjacent lower end 122 of post 102 to increase the stability of the mounting of post 102 to foundation 104 and/or provide a decorative structure adjacent the intersection of post 102 and foundation 104. System 200 further includes an upper rail structure 204 including an upper rail 206 which is substantially hollow and elongated between a first end 208 and second end 210 thereof. Rail structure 204 further includes rail mounting brackets 212A and 212B each mounted on a respective post 102. System 200 further includes lower rail structure 214 which includes a lower rail 216 which is substantially hollow and elongated between a first end 218 and second end 220 thereof. Lower rail structure 214 further includes a pair of rail mounting brackets 222A and 222B each mounted on a respective post 102 adjacent lower end 122 thereof. System 200 further includes a plurality of balusters 224 each elongated between an upper end 226 and a lower end 227 thereof. Each baluster 224 extends between upper rail 206 and lower rail 216 with baluster 224 adjacent upper end 226 being connected to upper rail 206 and adjacent lower end 227 connected to lower rail 216.

With reference to FIG. 7, upper rail 206, lower rail 216 and balusters 224 are further detailed. Upper rail 206 includes a pultruded structure 228 which serves as a substrate and a top coat 230. Pultruded structure 228 has a generally hollow T-shaped configuration. Pultruded structure 228 has an outer surface 232 and an inner surface 234. Inner surface 234 defines an upper interior chamber 236 which is generally T-shaped in structure and completely surrounded by inner surface 234 as viewed in cross-section although chamber 236 opens at each of first end 208 and second end 210 of upper rail 206. Interior chamber 236 is bound by a hollow trunk section 238 of pultruded structure 228 and a pair of hollow arms 240 which extend outwardly from trunk section 238 in opposite directions from one another. A lower side of chamber 236 is bound by a separating wall 242 at the base of trunk section 238. A pair of spaced projections 244 each extend from respective intersections of trunk section 238 and separating wall 242, said projections 244 extending downwardly and then inwardly to define a lower interior chamber 246 which opens downwardly. Lower interior chamber 246 receives upper ends 226 of balusters 224 with upper end 226 preferably abutting separating wall 242. Top coat 230 of upper rail 206 has an inner surface 248 bonded to outer surface 232 of pultruded structure 228 and a visible outer surface 250. Pultruded structure 228 and top coat 230 of upper rail 206 are formed in the same manner and of the same materials as described with regard to pultruded structure 148 and top coat 150 of upper rail 108 of fence system 100.

With continued reference to FIG. 7, lower rail 216 includes a pultruded structure 252 which serves as a substrate and a top coat 254. Pultruded structure 252 has an outer surface 256 and an inner surface 258 defining a lower interior chamber 260 which is substantially rectangular in cross-section. Interior chamber 260 is bound at an upper end by a separating wall 262. A pair of spaced projections 264 extend upwardly from separating wall 262 and then inwardly toward one another to define an upper interior chamber 266 which opens upwardly. Upper interior chamber 266 receives lower ends 227 of balusters 224 with lower ends 227 preferably abutting separating wall 262 and inwardly extending portions of each projection 264 closely adjacent each baluster 224 adjacent lower end 227. Top coat 268 of lower rail 216 has an inner surface bonded to outer surface 256 of pultruded structure 252 and a visible outer surface 270. Pultruded structure 252 and top coat 268 are formed in the same manner using the same materials as the other pultruded structures and top coats described earlier herein.

With continued reference to FIG. 7, each baluster 224 includes a pultruded structure 272 and a top coat 274. Pultruded structure 272 has an inner surface 276 defining an interior chamber 278 and an outer surface 280. Top coat 274 includes an inner surface 282 which is bonded to outer surface 280 of pultruded structure 272 and outer surface 284 which is visible between upper rail 206 and lower rail 216. Pultruded structure 272 and top coat 274 are formed in the same manner using the same materials as the other pultruded structures and top coats described previously.

The mounting of upper rail 206 and lower rail 216 on post 102 is substantially the same as that shown in FIG. 6 except for the differences associated with the different cross-sectional shapes of said rails. Lower rail 216 has substantially the same cross-sectional shape as lower rail 114 of system 100 except for the upwardly opening interior chamber 266. As a result of these cross-sections being substantially the same, the lower rail mounting brackets 222A and 222B are substantially the same as lower rail mounting brackets 116A and 116B of system 100. However, the upper rail mounting brackets 212A and 212B of system 200 vary from upper rail mounting brackets 110A and 110B of system 100 in that the interior chamber (not shown) for receiving respective ends 208 and 210 of upper rail 206 have a different configuration from interior chamber 170 of upper rail mounting brackets 110A and 110B of system 100. In particular, said interior chambers are substantially T-shaped with a mating configuration of outer surface 250 of top coat 230 of upper rail 206. Otherwise, rail mounting brackets 212A and 212B are substantially the same and most preferably have a visible outer surface as described with regard to system 100 which is made up of top coat 230 and a non-visible surface which is substantially free of top coat 230.

Thus, systems 100 and 200 provide a fence system in which at least one of the rails or posts are formed with a pultruded structure, preferably with a top coat mounted thereon and most preferably with the top coat being co-extruded with the pultruded structure as previously described. Most preferably, at least the rail or rails of the fence system include the pultruded structure as the rails of the previous art tend to be the most flexible portion of the fence system. However, using a pultruded structure for the posts alone also provides a substantial increase in strength with regard to the prior art posts. Any combination of the rails, posts and balusters being formed with a pultruded structure is within the scope of the present invention. Preferably, each of the members which includes a pultruded structure also includes a top coat and most preferably one co-extruded as described. In addition, it is preferred that the mounting brackets used include the substrate and top coat as described herein. This structure of the mounting brackets allows for accurate matching of the top coats used with the mounting brackets and the top coats used with the other structures which utilize the top coat. Most preferably, the top coat materials are the same, and thus are formulated to be used with extrusion as well as injection molding. As noted earlier, it is preferred that only the visible surface of the mounting brackets include the top coat, most particularly with regard to the more expensive materials such as an acrylic material.

It will be appreciated by one skilled in the art that a variety of changes may be made to the embodiments shown and described herein which are within the scope of the present invention. For instance, as illustrated by the two different embodiments, the railings may have varying shapes and overall configurations. Most preferably, all of the structures have an extrudable shape and this is a requirement for those structures which are formed by pultrusion or extrusion.

In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.

Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described. 

1. A fencing system comprising: a first post; a first rail mounted on the post; and at least one of the post and the first rail including a pultruded substrate comprising resin-embedded fibers.
 2. The system of claim 1 wherein the at least one of the post and the first rail includes a pultruded substrate comprising resin-embedded fibers and an extruded topcoat which are integrally formed as a one-piece member.
 3. The system of claim 2 wherein the topcoat is an acrylic material.
 4. The system of claim 2 wherein the topcoat is made of a PVC material.
 5. The system of claim 1 wherein each of the post and first rail includes a pultruded substrate comprising resin-embedded fibers and an extruded topcoat which are integrally formed as a one-piece member.
 6. The system of claim 1 wherein a rail mounting bracket is mounted on the post and supports a portion of the first rail whereby the first rail is mounted on the post; and wherein the rail mounting bracket includes a substrate and a topcoat.
 7. The system of claim 6 wherein the topcoat of each of the first rail and the rail mounting bracket is an acrylic material.
 8. The system of claim 7 wherein the rail mounting bracket has an outer surface which includes visible and non-visible surfaces when the bracket is mounted on the post and the rail is mounted on the bracket; and wherein the acrylic material forms the entire visible surface.
 9. The system of claim 8 wherein the non-visible surface is substantially free of the acrylic material of the topcoat of the rail mounting bracket.
 10. The system of claim 6 wherein the rail mounting bracket has an outer surface which includes visible and non-visible surfaces when the bracket is mounted on the post and the rail is mounted on the bracket; wherein the topcoat forms the entire visible surface; and wherein the non-visible surface is substantially free of the topcoat.
 11. The system of claim 2 wherein an injection-molded rail mounting bracket is mounted on the post and supports a portion of the first rail whereby the first rail is mounted on the post; and wherein the rail mounting bracket includes a substrate and a topcoat.
 12. The system of claim 11 wherein the substrate and topcoat of the rail mounting bracket are together a two-shot injection-molded member.
 13. The system of claim 1 wherein the first rail includes a first pultruded substrate comprising resin-embedded fibers and a first topcoat which is integrally formed with the first pultruded structure; and wherein a second rail is mounted on the post and includes a second pultruded substrate comprising resin-embedded fibers and a second topcoat which is integrally formed with the second pultruded structure.
 14. The system of claim 13 further including a plurality of balusters each extending between and mounted on the first and second rails; and wherein each baluster includes a pultruded substrate comprising resin-embedded fibers.
 15. The system of claim 13 wherein the first rail is an upper rail having first and second ends and being elongated between said ends; wherein the second rail is a lower rail having first and second ends and being elongated between said ends; wherein the upper rail defines a downwardly opening cavity extending from the first end thereof to the second end thereof; wherein the lower rail defines an upwardly opening cavity extending from the first end thereof to the second end thereof; and further including a plurality of balusters each having an upper end disposed in the downwardly opening cavity and a lower end disposed in the upwardly opening cavity.
 16. The system of claim 15 wherein the upper rail defines an interior chamber which is disposed above the downwardly opening cavity and which extends from the first end to the second end of the upper rail; and wherein the lower rail defines an interior chamber which is disposed below the upwardly opening cavity and which extends from the first end to the second end of the lower rail.
 17. The system of claim 16 wherein the upper rail includes a separating wall which separates the interior chamber thereof from the downwardly opening cavity; and wherein the lower rail includes a separating wall which separates the interior chamber thereof from the upwardly opening cavity.
 18. The system of claim 16 wherein the interior chamber of the upper rail is generally T-shaped.
 19. The system of claim 1 wherein the first rail includes a pultruded substrate comprising resin-embedded fibers.
 20. The system of claim 1 wherein each of the post and the first rail includes a pultruded substrate comprising resin-embedded fibers. 